Comfort molded bra cup

ABSTRACT

A brassiere having molded bra cups that have been factory-molded into predetermined cup size and shape, made of a mechanically frothed flexible shape memory molded elastomer, and having a polyurethane gel applied to or infused into the inside of the cup or around the underwire area to create a cooling sensation for the wearer.

FIELD OF THE INVENTION

This invention relates to brassieres and to methods and materials for making them.

BACKGROUND OF THE INVENTION

The current bras on the market are uncomfortable for wearers. They are hot; the straps apply undesired pressure; the underwire often pinches and pokes the wearer, and push-up bras exert undesired upward pressure on the breast.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention, there is presented a bra including molded bra cups that are factory-molded into desired cup size and shape. According to a preferred aspect of the invention, the molded bra cups may be flexible and/or deformable, but are made of shape-memory material and return their molded shape and size when application of force is removed.

According to an embodiment of the present invention, the bra cups may contain an integrally molded under breast support assembly which is made of a molded material that is more rigid than the molded material that makes up the remainder of the molded bra cup. According to a further embodiment of the invention, the molded outside profile of the bra cup may have a smooth and/or featureless transition between the integrally molded under breast support assembly and the remainder of the molded bra cup.

According to an embodiment of the present invention, the bra cups may be molded to receive an underwire assembly. According to one aspect of this invention, the bottom edge of the cup may be molded to include a groove, which groove is configured to receive an underwire assembly. According to various embodiments of the invention, the molded bra cup may be molded so that said groove is facing the wearer's ribs, or the molded bra cup may be molded so that said groove is facing upward (the interior of the cup, facing the underside of the wearer's breast) or downward (the exterior of the cup). According to one embodiment, said groove may be configured to be narrow at the opening/surface, e.g., less than 1-2 mm, and wider (e.g., 3-5 mm) in the interior so that some degree of force is required to insert the underwire assembly beyond the surface threshold of the groove into the wider interior. According to another embodiment of the invention, the molded bra cup may be molded to include a flap configured to conceal said groove.

According to another embodiment of the invention, the molded bra cup may be molded to have a shape that conceals the presence of an under wire assembly. According to one aspect of this embodiment, the bra cup may be molded to have a greater thickness in the area of the underwire and have a smooth external profile, with no lump or bump in the area that contains the underwire.

According to another embodiment of the invention, the molded bra cup of the invention may include one, two or more molded materials. According to an embodiment of the invention, a part of the molded bra cup that rests beneath the breast may be made of a first molded material and upper part(s) of the molded bra cup may be made of a second molded material. According to an embodiment of the invention, the molded material that rests beneath the breast may be somewhat less flexible and deformable than the molded material making up upper part(s) of the molded bra cup.

According to an embodiment of the invention, the molded bra cup of the invention may be partly or entirely sheathed in fabric. According to other embodiments of the invention, the molded bra cup of the invention may be configured to directly contact the skin of the wearer, i.e. is not sheathed in fabric or other material. According to alternative embodiments of the invention, the inside/body contacting side of the molded bra cup may be configured to contact the wearer's skin directly, i.e., is not sheathed or covered in fabric or other material, and the outside surface of the molded bra cup may be sheathed or covered in fabric or other material. According to further embodiments of the invention, the body contacting side of the molded bra cup may be covered or sheathed in a fabric or other material and the outside of the molded bra cup may be left uncovered.

According to another embodiment of the invention, the outside facing surface of the molded bra cup may have a molded texture. Non-limiting examples of molded textures include dimples, scales, and the like. According to another embodiment of the invention, the outside facing surface of the molded bra cup may include integrally molded features in the shape of a nipple or nipple and areole.

According to an embodiment of the invention, the molded bra cup is made of a mechanically frothed or foamed elastomer that is 2.5- or 3-dimensional molded into the desired bra cup shape and size. As discussed above, the molding process allows for single or multiple materials to be molded customizing the shape and feel.

According to a further embodiment of the invention, cooling materials, e.g., polyurethane gels, with or without a film covering, may be applied to or infused into the inside of the cup or around the underwire area to create a cooling sensation for the wearer.

According to still further embodiments of the invention, cooling materials and or frothed or foamed elastomers can be attached to the shoulder straps and or under the arms to spread the load on the wearer and provide cooling and or comfort.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an inside (body side) perspective view of a molded bra cup according to an embodiment of the invention.

FIG. 2 is an outside (clothing side) perspective view of a molded bra cup according to an embodiment of the invention.

FIG. 3 is an expanded view of a body side perspective view of a molded bra cup according to an embodiment of the invention containing a molded groove in the rib-facing edge of the bra cup for receiving an underwire.

FIG. 4 is an expanded view of a body side perspective view of a molded bra cup according to an embodiment of the invention containing a molded groove in a bottom facing surface of the bra cup for receiving an underwire.

FIG. 5 is an expanded view of a body side perspective view of a molded bra cup according to an embodiment of the invention containing a molded groove in a bottom facing surface of the bra cup for receiving an underwire, which groove is covered by a flap.

FIG. 6 is an expanded view of a body side perspective view of a molded bra cup according to an embodiment of the invention containing a molded groove in an upward facing (lower breast-facing) surface of the bra cup for receiving an underwire.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a molded bra cup 2 is shown with a molded support assembly 4. The molded support assembly may be integrally molded with the rest of the cup, or it may be molded separately from the cup and attached to the cup in post-molding operation. According to a preferred embodiment, the outside surface of the molded support assembly is flush with the contiguous outside surface 6 of the bra cup. The bra cup may be supported on the body by any known method, including shoulder, neck, and or back straps, and/or by adhesives (strapless). The bra cup may be molded by any known molding technology. See U.S. application Ser. Nos. 11/644,266 (the entirety of which is incorporated herein by reference), 12/423,174 (the entirety of which is incorporated herein by reference), and 13/008,471 (the entirety of which is incorporated herein by reference) for methods for molding articles. In particular, the molded bra cup is preferably made of a mechanically frothed or foamed elastomer, and may include integrally molded inner and/or outer film partially or entirely encasing the elastomer.

More specifically, the mechanically frothed gel elastomer is a non-aqueous gel elastomer (gel precursor) that has been mechanically frothed (without chemical blowing), dispensed and then allowed to cure. As mentioned, no blowing (gas producing) agents are used, and non-aqueous gel precursor polyol and additive systems are frothed using a froth mix head, either prior to, or after addition of the isocyonate, depending on desired speed of reaction and cell structure. According to a preferred embodiment, isocyanate is added after the material leaves the froth mix head. According to the embodiment in which the isocyanate is added after the material leaves the froth mix head, the isocyanate can be added to the froth using a static mixer. Catalyst can likewise be modified to affect the speed of the reaction, the safeness of the material to unprotected skin, and the cell structure. Fillers can be added to modify the tact, hardness and rebound time of the material. Catalysts and/or fillers may be added prior to frothing, or after frothing, before, during, or after addition of the isocyanate.

Following post-frothing mixing (if necessary), the frothed gel may be formed/cured into desired shapes using known molding techniques.

Once cured, the material retains its shape under compression and rebounds to original shape at a variable rate depending on chemistry and process. The material has a wonderful hand that gives a very different feel as compared to memory foams. Specifically, the material is surprisingly and exceedingly soft and extremely pliable, notwithstanding its shape memory characteristics. The frothed gel elastomer is particularly suitable for use in body-contacting applications where extreme softness combined with good recovery is paramount. The frothed gel of the invention is particularly suited for the manufacture of ear buds, ear muffs/ear phones, bras and bra inserts, and breast pads. Due to its unexpectedly superior softness and resiliency, the frothed gel of the invention is ideal for body contacting applications such as breast pads, cups and supports.

Referring to FIGS. 2-6, the bra cups may be molded to include a groove for receiving an underwire assembly. The bottom edge 8 of the cup may be molded to include a groove 10, which groove is configured to receive an underwire assembly. As shown in FIG. 3, the molded bra cup may be molded so that the groove 10 is facing the wearer's ribs. As shown in FIG. 6, the molded bra cup may be molded so that the groove 10 is facing upward (the interior of the cup/bottom of the wearer's breast). As shown in FIG. 4, the molded bra cup may be molded so that the groove 10 is facing downward (the exterior of the cup). The groove 10 may be configured to be narrow at the surface, e.g., less than 1-2 mm, and wider (e.g. 3-5 mm) in the interior (see FIG. 4) so that some degree of force is required to insert the underwire assembly beyond the surface threshold of the groove into the wider interior. According to an alternative embodiment (FIG. 5), another embodiment of the invention, the molded bra cup may be molded to include a flap configured to conceal said groove.

The molded bra cup may be molded to have a shape that conceals the presence of an under wire assembly. According to one aspect of this embodiment, the bra cup may be molded to have a greater thickness in the area of the underwire and have a smooth external profile, with no lump or bump in the area that contains the underwire.

The molded bra cup of the invention may include one, two or more molded materials. According to an embodiment of the invention, a part of the molded bra cup that rests beneath the breast may be made of a first molded material and upper part(s) of the molded bra cup may be made of a second molded material. According to an embodiment of the invention, the molded material that rests beneath the breast may be somewhat less flexible and deformable than the molded material making up upper part(s) of the molded bra cup.

According to various embodiments of the invention, the molded bra cup of the invention may be partly or entirely sheathed in fabric. According to other embodiments of the invention, the molded bra cup of the invention may be configured to directly contact the skin of the wearer, i.e. is not sheathed in fabric or other material. According to alternative embodiments of the invention, the inside/body contacting side of the molded bra cup may be configured to contact the wearer's skin directly, i.e., is not sheathed or covered in fabric or other material, and the outside surface of the molded bra cup may be sheathed or covered in fabric or other material. According to further embodiments of the invention, the body contacting side of the molded bra cup may be covered or sheathed in a fabric or other material and the outside of the molded bra cup may be left uncovered.

According to another embodiment of the invention, the outside facing surface of the molded bra cup may have a molded texture. Non-limiting examples of molded textures include dimples, scales, and the like. According to another embodiment of the invention, the outside facing surface of the molded bra cup may include integrally molded features in the shape of a nipple or nipple and areole.

According to a further embodiment of the invention, cooling materials, e.g., polyurethane gels, with or without a film covering, may be applied to or infused into the molded material on the inside surface of the bra cup or around the underwire area to create a cooling sensation for the wearer. For methods and structures relating to infusing polyurethane gel into molded foam materials, see U.S. Pat. No. 8,512,854, entitled, the entirety of which is incorporated herein by reference.

According to still further embodiments of the invention, cooling materials and or frothed or foamed elastomers can be attached to the shoulder straps and or under the arms to spread the load on the wearer and provide cooling and or comfort. 

1. A brassiere comprising: molded bra cups factory-molded into predetermined cup size and shape; comprising a first flexible shape memory molded elastomer.
 2. A brassier according to claim 1, further comprising an integrally molded under breast support assembly which is made of a molded material that is more rigid than said first flexible shape memory molded elastomer.
 3. A brassier according to claim 2, said bra cups comprising a molded outside profile having a smooth transition between the integrally molded under breast support assembly and said molded bra cup.
 4. A brassier according to claim 1 comprising bra cups molded in a shape configured to receive a support assembly.
 5. A brassier according to claim 4, said bra cups having a bottom edge configured to contact the wearer, said bottom edge molded to include a groove configured to receive an underwire assembly.
 6. A brassier according to claim 5, the molded bra cup molded so that said groove is facing the wearer's body.
 7. A brassier according to claim 5, the molded bra cup molded so that said groove is facing upward.
 8. A brassier according to claim 5, the molded bra cup molded so that said groove is facing downward.
 9. A brassier according to claim 5, wherein said molded groove is configured to be narrow at the surface, and wider in the interior.
 10. A brassier according to claim 5, said molded bra cup molded to include a flap configured to conceal said groove.
 11. A brassier according to claim 1, the molded bra cup molded to have a shape that conceals the presence of an under wire assembly.
 12. A brassier according to claim 11, the bra cup molded to have a greater thickness in the area of the underwire and have a smooth external profile.
 13. A brassier according to claim 1, the molded bra cup comprising mechanically frothed elastomer.
 14. A brassier according to claim 1, said bra cup further comprising a polyurethane gels applied to or infused into the inside of the cup or around the underwire area to create a cooling sensation for the wearer. 